Method and apparatus for shaping



April 4, 1944. w. P. HILL METHOD AND APPARATUS FOR SHAPING MEMBERSOriginal Filed April 27, 1942 2 Sheets-Sheet 1 INVENTOR.

WALTER P. HlLL E. III II IIIIQ ATTORNEYS April 4, 1944. w R HlLL Re.22,465

METHOD AND APPARATUS FOR SHAPING MEMBERS Original Filed April 2'7, 19422 Sheets-Sheet 2 mvmroza. WALTER F! HILL MMNWW ATTORNEYS I seams Apr,4,1944

METHOD AND APPARATUS FOR SHAPING Walter P. Hill, Detroit, Mich,assignor, by niesne assignments, to Calumet and Heola ConsolidatedCopper Company, Calumet, Mich, a

corporation o! Michitan No. 2,313,474, dated March 9, 1943, SerialOriginal No. 440,713, April 27, 1942. Application for More particularly.this invention relates to a method and a tool for shaping stock toconform the latter to the contour, of a portion of the tool and is acontinuationin part o'f'my copending application, Serial No. 366,757,flled November 22, 1940.

One oi the principal objects of this invention is to control the flow ordistribution of the stock during the iorming operation in such a mannerthat the stock may be deformed to a substantial degree without thedanger of overheating or otherwise injuring the stock.

In accordance with this invention, sufllcient pressure is initiallyexerted around the entire circumference of the stock toprogressivelyheat the stock to a plastic condition and thereafter aforming pressure is exerted on a continuous area of the stock extendingover a major portion of the circumference of the stock while leaving theremaining portion free to deiormin response to the forming pressure. Thearrangement is such that successive portions of the stock are free todistort or deform during the forming operation and this is desirablebecause it prevents seizure between the stock and tool due to thermalexpansion.

Another object of this invention is to provide a tool having a heatring" for exerting the required initial pressure on the stock to heatthe latter and having a relief area in the forming portion to enablesuccessive portions or the stock to deform or distort during the formingoperation.

A further object of this invention is to thoroughly work the stockduring the forming operation by one or more of the edges defining therelief portion of the tool. As a result, the stock is maintained in aplastic or easily workable condition and distribution of the stock iscontrolled to obtain the desired stock thickness in the completedarticle.

In addition to the foregoing, this invention contemplates a toolrendering it possible to close the ends of relatively large diametertubes or casings and, at the same time, enables thickening the metal atthe closed ends to practically any specifled thickness. This feature ofthe invention is highly advantageous because it offers the possibilityof eliminating the orthodox forging processes which were heretoforerequired in the manulacture of thickened closed end tubes or casingswhich are extremely expensive and very slow from a productionstandpoint.

Still another object of this invention is to form the stock to apredetermined length and internal diameter during the forming operation.

The foregoing, as well as other objects, will be reissue March 15, 1943,Serial No. 419,214:

14 Claims. (0!. 153-21) made more apparent as this description proceeds,especially when considered in connection with the accompanying drawings.wherein:

Figure 1 is a side elevation of a reducing tool constructed inaccordance with this invention;

Figure 2 is a top plan view of the tool shown in Figure 1;

Figure 3 is a sectional view taken substantially on the line 1-3 ofFigure 2 and showing a piece of stock engaged by the tool;

Figure 4 is a cross sectional view taken on the line H of Figure 3;

Figure 4A is a cross sectional view similar to Figure 4 showing amodified form of construction;

Figure 5 is an elevational view partly in section 0! a portion 0! onearticle capable of being produced by this invention;

Figure 8 is a sectional view through a slightly modified form oi tool;

Figure 7 is a cross sectional view taken substantially on the line 1-1of Figure 6;

Figure 8 is a top plan view of a further embodiment of this invention;

Figure 9 is a sectional view taken on the line 9-9 of- Figure 8;

Figure 10 is an end elevational .view of the construction shown inFigure 8;

Figure 11 is a longitudinal sectional view illustrating a Iurtherembodiment 01 this invention; and

Figure 12 is a cross sectional view taken substantially on the planeindicated by the line l2--l 2 of Figure 11.

Referring generally to the embodiments of the invention shown in Figures1 to 7, inclusive, 10 and 11, it will be noted that in each of thesemodifications a length of tubular stock is fashioned to the contour ofthe tool by exerting a reducing pressure on the stock as the latter andtool are relatively rotated and moved in directions toward each other.Briefly, each of the tools is provided with a continuous annular portionA which gradually decreases in cross section and exerts a reducingpressure continuously around the entire circumference of the stock toprogressively heat the latter to a plastic or easily workable condition.y

The stock leaving the annular heating portion A enters a cavity B alsoformed in the tool and has a portion which progressively decreases incross section longitudinally of the tool. This portion of the cavity isformed with a relief recess C which extends longitudinally substantiallythroughout the length of the cavity B and has an area which isrelatively small as compared to the area of the stock confining wallportion of the cavity. As a result, the wall portion of the cavityexerts a reducing pressure on a continuous area extending over a majorportion of the circumference of the stock and the remaining portion ofthe stock-is free to deform into the relief recess in response to thereducing pressure.

By providing the relief area, seizure between the stock and tool due tothermal expansion is eliminated and the excess metal resulting from thereduction in cross-section of the stock is accommodated and allowed toremain in a plastic state, but is not overheated. The reductioncontinues in accordance with the confining portion of the tool and inaccordance with the shape of the tool until it is arrested by eitherdiscontinuing the operation of the tool or by a positive stop providedfor this purpose.

It will also be noted that as successive portions of the stock deforminto the relief recess, the stock is thoroughly worked by one or bothlongitudinal edge portions of the recess and, as a result, is maintainedin a plastic or easily workable condition, which permits uniform orcontrolled distribution of the stock to obtain the desired configurationand thickness in the completed article.

All of the above principles may be individually or collectively used toadvantage in working stock of metallic or non-metallic material tovarious different shapes and specified sizes. However, in order to moreclearly illustrate the invention, I have shown in Figure one type ofarticle capable of being inexpensively produced from a length of tubularstock with the minimum number of operations and with relatively simpleapparatus. The article in Figure 5 comprises a body ll of tubing havingone end fashioned to form an inwardly tapering portion II and having areduced annular nipple l3 projecting axially from the tapering portion Il. The tubing may be ferrous, non-ferrous or plastic, and the nipple maybe of any desired length. In fact, the entire length of the tubularstock may be reduced to the size of the nipple I I if desired.

With the above in mind, reference will now be made more in detail to thetool illustrated in Figures 1 to 4, inclusive. The tool is in the formof a female die It having an entrant opening I5 of sufilcient diameterto receive one end of the tube I0 and having an axially extending boreII connected to the entrant opening I! by the cavity B and heat ring C.The cavity B and heat ring C progressively decrease in cross sectionalarea from the entrant opening I! to the bore I1 and cooperate to formthe flared portion ll of the article shown in Figure 5. The reduced borel'l forms the nipple l3 of the article having an external diameterdetermined by the internal diameter of the bore II and having a lengthdetermined by an adjustable stop ll slidably supported in the bore II.It will further be noted from Figures 1 to 4, inclusive, that the toolII is provided with at least one relief portion C, illustrated in thedrawing as an open segment, in the form of a slot or groove extending inthe direction of the axis of the tool and having a length closelyapproximating the length of the working zone or area of the tool. Thepurpose of the relief portion or portions 0 is to relieve the reducingpressure on successive portions of the tube Ill and permit relativelyfree distortion or expansion of the stock into the relief portionthroughout the extent of working 01' the tube,

Assuming for the purpose of illustration that the tool is moved aboutits axis in a clockwise direction as viewed in Figure 4, it will benoted that the edge 20 of the relief portion C works the tubular stockto not only "iron out" any enlargement of the tube but to, also, controlthe distribution of the stock. It follows, of course, that in the eventof the tool is moved about the axis in the opposite or in acounterclockwise direction, as viewed in Figure 4, the edge 20' of therelief portion C worls the stock in a similar manner. In fact, both theedges Ill and 20' may be employed to work the tubular stock as thelatter and tool are relatively angularly moved about the axis of thetool. In Figure 4A, I have shown the edge 20' of the relief portion C asextending into the cavity of the die or tool. Assuming for the purposeof explanation that the tool is moved about its axis in a clockwisedirection as viewed in Figure 4A, it will be noted that the stock isworked by the edge 20' of the relief portion as well as by the edge Ill.

The tool I and tube ID are not only supportedfor relative movement aboutthe axis of the tool but are, also, relatively movable toward each otherto extend one end of the tube Ill into the entrant opening IS in thetool. As the free end of the tube Ill engages the inwardly tapering wallof the cavity B, the end of the tube is engaged by one or the other ofthe edges 20 and 20' (depending upon the direction of oscillationor.rotation of the tool and tube) and the end of the tube is shaved toform the same perfectly square. It may also be pointed out at this timethat the edge 2| of the relief portion C of the tool is spaced from theouter end of the entrant opening it to form the continuous annulartapered heat ring A which exerts a continuous initial reducing pressurearound the entire circumference of the stock as the latter and tool arerelatively moved in directions toward one another. As a result, thestock is progressively heated to a plastic or workable condition as itenters the cavity B and the extent to which the stock is heated may becontrolled by varying the location of the edge 2| rialative to the outerend of the entrant opening I As relative movement of the tool I4 andtube l0 continues in directions toward each other, the

tapering portion ii of the tool applies a reducing pressure on thestock, and the tool as a whole controls the flow and distribution of thestock and forms the end portionthereof to the contour of the tool. Asstated above, the pressure is relieved on successive portions of thestock during the forming operation by the relief portion 0 in the tooland, as a result, these portions are free to enlarge or deform into therelief portion C. As successive portions of the stock are displaced intothe relief portion C, the stock is effectively worked by either or boththe edges Ill and 20' of the relief portions, and the thickness of thestock is controlled within close limits. It will also be apparent,especially when considered in connection with Figure 4, that thethickness of the walls of the stock may be reduced, if desired, byactually shaving the stock with the trailing edge of the relief portionC during the forming operation.

The feeding operation is continued until the free end of the tube abutsthe adjustable stop II which is located in the bore I! in a positionpredetermined in dependence upon the desired length of the nipple l3.Particular attention is again called to the fact that the relief portion0 extends from a position in close proximity to diameter of the plishedis by providing one or more .tion to the tool the entrant end of thecavity 13 of the tool to the stop ll so that the stock is effectivelyworked during the forming operation and distribution of the stock iscontrolled. It may be pointed out at this time that by extending therelief portion C along the nipple ll, the exterior surface of the lattermay be formed to within every close limits of a specified diameter byburnishing the same with one or the other of the edges 2| and II of therelief portion C.

Reference has been made above to the fact that the entire tube ll may bereduced to the bore l1. From the foregoing, it will be apparent that thelength of the tube ll may be reduced to the size of the bore H by merelyeliminating the stop ll. The elimination of this stop permits unlimitedrelative feeding of the tool i4 and the tube II to form a continuouslength of reduced tubing.

In some cases it may be desirable to provide additional stock in thezone of the forming operation, and one way that this may beaccomindentations 22 in the tapered surface I! of the tool. Theseindentations permit the stock to "pile up" during the forming operation,and this stock is uniformly distributed by either or both of the edges2. and 2|! of the relief portion C. As a result, the thickness of thewalls of the stock is increased in proportion to the amount of stockgathered by the indentations 22.

In some cases it may be advantageous to form the internal diameter ofthe nipple I! to a specifled size, and this may be accomplished by thetool shown in Figures 6 and I. As shown in the above figures, the tool23 is similar in construc ll previously described with the exceptionthat a mandrel 24 is located in the reduced bore of the tool inconcentric relation to the latter. The forward end of the mandrel 24 hasone or more relief portions and is adapted to extend into the nipple II.The edges 28 of the relief portions in the mandrel 24 cooperate toburnish or shave the inner surface of the reduced portion II to form thelatter to a predetermined internal diameter. It follows, therefore, thatthe mandrel 24 cooperates with one or the other of the edges 20 and 20'of the relief portion C, extending along the reduced bore, to fashionthe outside and inside diameters of the nipple to specified dimensions.

In Figures 8 to 10, inclusive, of the drawings, I have illustrated atool capable of working one end of a tube to close the latter end and,if desired, to also thicken the same. In detail, the tool 34 is providedwith a recess or cavity 35 and with one or more relief portions 36 whichextend to the axis of the tool in a manner clearly shown in Figure 10.The relief portion 36 performs the same results and operates in the samemanner as the relief portion C previously described in detail. Inaddition, the tool 34 is provided with a continuous annular heat ring35' for progressively heating the stock by exerting a reducing pressurecontinuously around the entire circumference of the stock as the latterenters the cavity or recess 35. This heat ring 35' is the equivalent ofthe heat ring A previously described and operates in the same manner asthe latter to initially heat the stock to a plastic or easily workablecondition.

The highly effective metal working and distribution characteristics ofthe tool previously described renders it possible to effectively closethe ends of casings or tubes having a diameter and ing portion of thetool.

wall thickness of such magnitude that it was heretofore necessary by aforging process which is not only considerably more expensive but isalso much slower. Moreover, due to the nature of the stock distributingand control means, it is also possible to form the end of the tube orcasing to various thicknesses and this is desirable in manufacturingcertain types of articles such, for example, as shell casings.

The embodiment of the invention shown in Figures 1i and 12 illustrates atool 31 for forming a return bend 38 in a length of tubular stock. Indetail the tool 31 is provided with a reduced axially extending portion3! which is surrounded by an annular recess 40 corresponding indimension to the desired size of the return bent II. The annular portion31 acts to heat and partially reduce the stock in the same manner as theportion A in Figures -1 to 4. In addition, the tool is fashioned with atleast one relief portion 4 I which extends into the reduced portion 39or, in other words, extends throughout the length of the work- As aresult, the" relief portion ll performs the same functions as the reliefportion C, described in the first embodiment of the invention, in thatit permits distortion and working of the stock to form the latter to thecontour of the tool. In this connection, it will be noted from Figure 12that the opposite side edges of the relief portion ll correspond incontour to .the return bent portion 38 of the stock, and one or theother of the edges of the relief portion controls the distribution ofthe stock as the latter is worked by the tool. It may also be pointedout that the edges of the relief portion formed in the reduced-part 39of the tool acts on the inner surface of the return bent portion andforms the same to a predetermined specified dimension.

What I claim as my invention is:

1. The method of forming stock which includes the steps of exerting areducing pressure on a continuous area extending over a major portion ofthe circumference of the stock while leaving the remaining portion freeto deform in response to the reducing pressure, and relatively rotatingthe stock and pressure exerting means thereby permittingcircumferentially progressive deformation longitudinally of the stock inthe area out of contact with the pressure exerting means.

2. The method of forming stock which includes the steps of progressivelyheating and partially reducing the stock by exerting a reducing pressurecontinuously around the entire circumference of the stock by a rotatingmeans, and immediately further reducing the stock and workin anddistributing the material thereof by exerting a reducing pressure by arotating means on a continuous area extending over a major portion ofthe circumference of the stock while leaving the remaining portion freeto deform in response to the reducing pressure.

3. The method of forming stock which includes the steps of progressivelyheating and partially reducing the stock by exerting a reducing pressurecontinuously around the entire circumference of the stock by a rotatingmeans, immediately and working the material thereof by exerting areducing pressure on a continuous area extending over a major portion ofthe circumference of the stock while leaving the remaining portion freeto deform in response to the reducing pressure, and relatively rotatingthe stock and presto manufacture the same further reducing the stocksure exerting means thereby permitting cir-' cumferentially progressivedeformation longitudinal-1y of the stock.

4. Those steps in the method of shaping. tu-

bular stock which consist in simultaneously relatively rotating thestock and a shaping tool about theaxis of the tool while relativelymoving the tool and stock toward one another, initiallyclrcumferentially confining the stock continuously around the entirecircumference thereof by said shaping tool to heat and partially conformthe stock to the shape of the shaping tool, and immediately thereafterconfining the stock on a continuous area extending over a major portionof its, circumference sufiicient to conform the stock to the shape ofthe shaping tool while relieving the confinement of the stock for apredetermined area longitudinally of the tool to thereby permitdistortion of longitudinal portions of the stock into said relief areaduring the shaping operation.

5. Those steps in the method of shaping tubular stock which consist insimultaneously relatively rotating the stock and a shaping tool aboutthe axis of the tool while relatively moving the tool and stock towardone another, initially circumferentially confining the stockcontinuously around the entire circumference thereof by said shapingtool to heat the stock to permit subsequent control of the distributionof the stock, and while the stock is so heated confining the stock on acontinuous area extending over a major portion of its circumferencesufiicient to conform the exterior of the stock to the shape of theshaping tool while relieving the confinement of the stock for apredetermined area longitudinally of the tool to thereby per-' mitdistortion of longitudinal portions of the stock into said relief areaduring the shaping operation, and controlling distribution of the stockby the shape of the tool to control the wall thickness thereof.

6. Those steps in the method of shaping tubular stock without theapplication of external heat during the shaping operation which consistin simultaneously relatively rotating the stock and a shaping tool aboutthe axis of the tool while relatively moving the tool and stock towardone another, initially circumferentially confining the stockcontinuously around the entire circumference thereof by said shapingtool to heat the stock to permit subsequent control of the flow of thestock, and while the stock is so heated confining the stock on acontinuous area extending over a major portion of its cir cumferencesufllcient to conform the exterior of the stock to the shape of theshaping tool while relieving the confinement of the stock for apredetermined area longitudinally of the tool to thereby permitdistortion of longitudinal portions of the stock into said reliefshaping operation, and controlling the flow of the stockby the confiningand relief areas of the tool 7. Those steps in the method of shapingtubular stock without the application of external heat during theshaping operation which consist simultaneously relatively rotating thestock and a shaping tool about the axis of the tool while relativelymoving the tool and stock towards one another, initiallycircumferentially confining the stock continuously around the entirecircumference thereof by said shaping tool to heat and partially conformthe stock to the shape of the shaping tool, and immediately thereafterconfining the stock on a continuous area extending over a major portionof its circumference sumcient to conform the stock to the shape of theshaping tool while relieving the area during the confinement of thestock for a predetermined area longitudinally of the tool to therebypermit distortion of longitudinal portions of the stock into said reliefarea during the shaping operation, and controlling the flow of the stockby m the confining and reliei'areas of the tool.

8. A forming tool for reducing stock having an axially extending cavityat least a portion of which is of progressively diminishing crosssection longitudinally of the tool, the wall of said u cavity beingadapted to engage and reduce the stock upon relative rotation and axialmovement toward one another of the stock and tool, said wall beingprovided with a relief recess extending longitudinally substantiallythroughout the length go of said cavity, the area of the stock engagingwall of the cavity being substantially greater than the area of saidrelief recess whereby a major portion of the circumference of the by thetool during the reducing operation leaving a the remaining portion freeto deform into said relief recess in response to the reducing operation.

9. A forming tool for reducing stock having a continuous annular portionadapted to engage the stock throughout its circumference to partiallyreduce and heat the stock upon relative rotation and axial movementtoward one another of the stock and tool, and a second reducing portionhaving an axially extending cavity at least a ,5 portion of which is ofprogressively diminishing cross section longitudinally of the tool, thewall of said cavity being adapted to engage and reduce the stock uponrelative rotation and axial movement toward one another of the stock andtool, said wall being provided with a relief recess extendinglongitudinally substantially throughout the length of said cavity, thearea of the stock engaging wall of the cavity being substantiallygreater than the area of said relief recess whereby a major portion ofthe circumference of the stock reducing operation.

10. A forming tool for reducing stock having an axially extending cavityat least a portion of which is of progressively diminishing cross secthetool, the wall of said cavity being adapted to engage and reduce thestock upon relative rotation and axial movement toward one another ofthe stock and tool, said wall being provided with a relief recessextending longitudinally substantially throughout the length stock isengaged said wall being provided with a relief recess .ex-

7 tending longitudinally substantially throughout the length of 'saidcavity, the area of the stock engaging wall of the cavity beingsubstantially greater than the area of said relief recess whereby amajor portion of the circumference of the stock is engaged by the toolduring the reducing operation leaving the remaining portion free todeform into said relief recess, and means coaxial with said cavityadapted to extend into the stock to control the internal diameterthereof.

12. A forming tool for reducing stock having an axially extending cavityat least a portion of which is of progressively diminishing crosssection longitudinally of the tool, the wall of said cavity beingadapted to engage and reduce the stock upon relative rotation and axialmovement toward one another of the stock and tool, said wall beingprovided with a relief recess extending longitudinally substantiallythroughout the length of said cavity, the center line of said reliefrecess and the axis of the tool being substantially in the same plane,the area of the stock engaging tion having an axially extending cavityat least a portion of which is of progressively diminishing crosssection longitudinally of the tool, the wall of said cavity beingadapted to engage and reduce the stock upon relative rotation and axialmovement toward one another of the stock and tool, said wall beingprovided with a relief recess extending longitudinally substantiallythroughout the length of said cavity, the center line of said reliefrecess and the axis of the tool being substantially in the same plane,the area of the stock engaging wall of the cavity being substantiallygreater than the area of said relief recess whereby a major portion ofthe circumference of the stock is engaged by the tool during thereducing operation leaving the remaining portion free to deform intosaid relief recess, one of the edges defining the juncture of the cavitywall and relief recess being shaped to work the stock during saidreducing operation.

14. In a method of forming stock, the steps of relatively moving saidstock and a forming tool simultaneously in axial and rotationaldirections, initially partially reducing and frictionally heating thestock by a portion of said tool extending around the entirecircumference of the stock, and immediately thereafter exerting aconfining and progressively reducing pressure upon the circumference ofthe'stock on opposite sides of the center thereof by another portion ofsaid tool while leaving a segment of said circumference less than thediameter of the stock at each stage of its progressive reduction free todeform in response to and slightly in relief of said pressure.

WALTER P. HILL.

